Festo CP Lab User manual

Festo Didactic

CP Lab

03/2017

CPLab®

Manual

CP Lab conveyor

2 © Festo Didactic CP Lab conveyor

Order-No.:

Date: 07/2017

Layout: 07/2017, Schober

Filename: CP-L-CONV-GB-A001.doc

Internet: www.festo-didactic.com

E-Mail: [email protected]

Note

Where only pronouns such as he and him are used in this manual, these pronouns are of course

intended to refer to both male and female persons. The use of a single gender should not be

construed as gender discrimination; it’s intended solely to make the manual easier to read and the

formulations easier to understand.

Intended use

This installation was developed and manufactured for use in basic and further training in the fields

of automation and communications. The training company and/or the training staff must ensure

that the trainees observe the safety precautions.

Festo Didactic accepts no liability for injury or harm to trainees, the training company and/or any

third parties occurring when the installation is used for any purpose apart from training, except

Festo Didactic has caused such injury or harm intentionally or by grossly negligence.

At CP factory installations, it is not permissible to experiment with hazardous live voltages.

Reproduction, distribution and utilisation of this document, as well as the communication of its

contents to others without explicit authorisation, are prohibited. Offenders shall be held liable for

registered design applications.

Furthermore this manual describes setup and possible uses of the singular stations. It contains all

information and data required for commissioning, maintenance and operation.

Content

1 General safety instructions ________________________________________________________________ 5

1.1 Pictograms _________________________________________________________________________ 6

1.2 Safety sockets ______________________________________________________________________ 7

1.3 Note to electrical access of facility ______________________________________________________ 7

1.4 Handling the system _________________________________________________________________ 8

1.4.1 Dangers in handling the machine ___________________________________________________ 8

1.4.2 Safety precautions in standard operation _____________________________________________ 8

1.4.3 Dangers due to electric current _____________________________________________________ 8

1.4.4 Dangers due to pneumatic energy ___________________________________________________ 8

1.4.5 Maintenance – Servicing – Malfunction removal ________________________________________ 8

1.4.6 Organizational measures __________________________________________________________ 9

1.5 Personnel __________________________________________________________________________ 9

1.5.1 Notes on personnel _______________________________________________________________ 9

1.5.2 Training operations _______________________________________________________________ 9

1.5.3 Outside training operations ________________________________________________________ 9

1.6 Obligations of the operating company ___________________________________________________ 9

1.7 Obligations of the trainees ____________________________________________________________ 9

2 Introduction ___________________________________________________________________________ 10

2.1 Warranty and liability ________________________________________________________________ 10

2.2 Important notes ____________________________________________________________________ 10

2.3 General information CP Lab system ____________________________________________________ 11

2.3.1 Application modules _____________________________________________________________ 12

2.4 Resources _________________________________________________________________________ 19

3 Design and function ____________________________________________________________________ 21

3.1 Transport _________________________________________________________________________ 21

3.2 Set up ____________________________________________________________________________ 21

3.2.1 General information _____________________________________________________________ 21

3.3 The CP Lab conveyor ________________________________________________________________ 22

3.4 Stopper unit _______________________________________________________________________ 24

3.5 Drive variants ______________________________________________________________________ 26

3.6 Signal generator ____________________________________________________________________ 28

3.7 Electrical connections _______________________________________________________________ 29

3.8 Connecting a CP Lab ________________________________________________________________ 31

3.8.1 Pneumatic Commissioning ________________________________________________________ 31

3.8.2 Electrical Commissioning _________________________________________________________ 32

3.8.3 Modus switch __________________________________________________________________ 33

3.8.4 Emergency Stop System __________________________________________________________ 34

3.9 Extended functions with applications ___________________________________________________ 35

3.9.1 Assembly of the application _______________________________________________________ 35

3.9.2 Pneumatic connection of applications _______________________________________________ 37

3.9.3 Electrical connection of applications ________________________________________________ 38

3.10 Commissioning ____________________________________________________________________ 42

4 Operation _____________________________________________________________________________ 43

4.1 Software Siemens __________________________________________________________________ 43

Content

4 © Festo Didactic CP Lab conveyor

4.1.1 Compile the device configuration __________________________________________________ 43

4.1.2 Load device configuration into PLC _________________________________________________ 43

4.2 Software Festo _____________________________________________________________________ 47

4.2.1 Find and select the PLC ___________________________________________________________ 47

4.2.2 Download the project ____________________________________________________________ 51

4.2.3 The PLC can be reset _____________________________________________________________ 55

4.3 Menu structure of the CP Lab screen ___________________________________________________ 57

4.3.1 Menu prompting ________________________________________________________________ 58

4.4 Operation _________________________________________________________________________ 65

4.4.1 Message line and window ________________________________________________________ 67

4.4.2 Display of objects _______________________________________________________________ 68

5 Components __________________________________________________________________________ 69

5.1 Touch panel _______________________________________________________________________ 69

5.1.1 Front PCB XZ1 __________________________________________________________________ 70

5.1.2 Back PCB XZ2 __________________________________________________________________ 71

5.1.3 SYS link Cable - Interface _________________________________________________________ 73

5.1.4 RFID Read/Write system __________________________________________________________ 74

5.1.5 IO-Link DA-Interface (digital-analogue interface) ______________________________________ 75

5.1.6 Control systems ________________________________________________________________ 76

5.1.7 Signal Converter ________________________________________________________________ 78

5.1.8 Solenoid valve __________________________________________________________________ 80

6 Extensions ____________________________________________________________________________ 81

6.1 Extension with an active corner ________________________________________________________ 81

6.2 Extension with a passive corner _______________________________________________________ 83

General safety instructions

1 General safety instructions

The laboratory or the classroom must be equipped in accordance with EN 50191:

 An emergency off device must be provided.

– At least one emergency off device must be located within, and one outside of the test area.

 The test area must be secured against unauthorised start-up.

– For example with a key switch

 The test area must be protected by residual current devices (RCDs).

– Type B residual current circuit breaker with a residual current rating of ≤ 30 mA

 The test area must be protected by overcurrent protection devices.

– Fuses or circuit breakers

 The test area must be overseen by a supervisor.

– A supervisor is a qualified electrician or a person who has received appropriate instruction, has

knowledge of the respective safety requirements and safety regulations and whose training has been

accordingly documented.

 No damaged or defective devices may be used.

– Damaged devices must be barred from further use and removed from the test area.

General requirements for safe operation of the devices:

 Do not lay cables over hot surfaces.

– Hot surfaces are identified with a corresponding warning symbol.

 Maximum permissible current loads for cables and devices must not be exceeded.

– Always compare the current ratings of the device, the cable and the fuse.

– In the event that these are not the same, use a separate upstream fuse in order to provide

appropriate overcurrent protection.

 Devices with an earth terminal must always be grounded.

– If an earth connection (green-yellow laboratory socket) is available, it must always be connected to

protective earth. Protective earth must always be connected first (before voltage), and must always be

disconnected last (after voltage).

 If not otherwise specified in the technical data, the device is not equipped with an integrated fuse.

General safety instructions

6 © Festo Didactic CP Lab conveyor

1.1 Pictograms

This document and the described hardware include warnings concerning possible hazards which may arise if

the system is used incorrectly. The following pictograms are used:

Warning

Non-observance of this pictogram may result in serious personal injury or damage

to property.

Caution

Non-observance of this pictogram may result in personal injury or damage to

property.

Warning

This pictogram indicates that the device must be switched off and its mains plug

must be removed from the electrical outlet before installation, repair, maintenance

and cleaning work. Observe the manual, in particular all safety instructions. Non-

observance may result in severe personal injury or damage to property.

Warning

This pictogram indicates danger of being burned if hot surfaces (up to roughly

85 C) are touched.

Important

This symbol emphasizes important information for correct machine handling.

Failure to pay attention to this symbol may result in damages to the machine or to

its surroundings.

i

Information

This symbol indicates operational tips and especially useful directions. This

symbol assists you to make optimal use of all of your machine’s functions.

General safety instructions

1.2 Safety sockets

If not otherwise specified in the technical data, the following colour codes apply to the power supply and

signal connections for components included in Festo Didactic’s learning system for automation and

technology.

Colour

Function

Colour

Function

Voltage greater than SELV

e.g. line voltage of 90 to 400 V AC per conductor

(grey)

24 V DC

(red)

Neutral conductor

(grey/blue)

0 V DC

(blue)

Protective conductor

(green-yellow)

Safety extra-low voltage,

signal input/output

(black)

The specified protection class and safe use can only be assured if laboratory safety cables supplied by Festo

Didactic are used.

Damaged laboratory safety cables must be immediately barred from further use

and removed from the test area.

1.3 Note to electrical access of facility

According to EN 60204-1 (VDE 0113-1) part 8.2.8, a supply cable with an additional protective conductor is

required for the supply of the CP factory installations. Since a leakage current of >10mA can flow depending

on the configuration, an additional protective conductor with 10mm² is necessary.

Please see also DIN EN 60204-1.

General safety instructions

8 © Festo Didactic CP Lab conveyor

1.4 Handling the system

1.4.1 Dangers in handling the machine

The installation has been constructed technologically up to date and in conformance with the recognized

rules of safety engineering. Nevertheless, during operation it is possible that harm might be caused to the

user or third parties or that the installation or other property might get damaged. Therefore, the installation

has to be handled according to specified operational use in perfect technical condition only.

Safety endangering malfunctions cannot be tolerated during training and have to be removed immediately.

The system is to be used only:

 for its intended purpose and

 In absolutely safe conditions.

Faults impairing safety must be rectified immediately!

1.4.2 Safety precautions in standard operation

Put the installation into operation only, once all of the protection settings are completely functional.

At least, before starting operation, check the installation for externally visible damages and for the reliability

of the safety devices.

Do not grip into the installation while in operation.

Before circuit construction, circuit disassembly and circuit modification: switch off air pressure and power

supply.

General safety regulations are to be observed: DIN 58126 and VDE 0100.

1.4.3 Dangers due to electric current

As soon as maintenance is completed, check the function reliability of the safety devices.

Only trained experts in electric or electronic engineering are permitted to carry out work on the electric

supply system.

The terminal boxes are to be kept closed at all times. Access must be permitted only under supervision of a

member of the training staff.

Do not activate electric limit switches manually during fault search. Tools are to be used.

Only low voltage 24VDC is to be used.

1.4.4 Dangers due to pneumatic energy

Accidents might occur due to bouncing off tubes, caused by air pressure. Interrupt air pressure supply

immediately. Caution! When the air pressure supply is activated, cylinders may move in or out.

Do not uncouple any tubes under air pressure supply. Exception: Fault finding. In this case, keep on holding

the end of the tube. Do not exceed the permitted operating pressure. See data sheets.

1.4.5 Maintenance – Servicing – Malfunction removal

Carry out adjustments and inspections as instructed, in accordance with the specified intervals. (see

Datasheets)

Secure the compressed air and electricity supplies to prevent unintentional start-up. During inspections,

maintenance and repair work, the machine must be de-energized, de-pressurized and secured against

unexpected restart. All screw connections released during maintenance, inspection or repair work must be

checked to ensure correct re-tightening.

General safety instructions

1.4.6 Organizational measures

All existing safety devices must be checked at regular intervals.

1.5 Personnel

1.5.1 Notes on personnel

Basically two situations have to be considered, concerning matters on personnel.

 Activities during training operations

 Activities outside training operations

1.5.2 Training operations

Trainees are permitted to work with the machine only under strict supervision of an experienced person or

an instructor.

Activities of trouble-shooting and fault correction are to be checked by the instructor. Special care should be

taken regarding safety aspects.

1.5.3 Outside training operations

Activities in the areas of maintenance, service and repair are to be carried out by only persons with

appropriate technical qualifications.

1.6 Obligations of the operating company

The operating company undertakes to allow only those persons to work with the system who:

 Are familiar with the basic regulations regarding work safety and accident prevention and have been

instructed in the use of the system

 Have read and understood the chapter concerning safety and the warnings in this manual

Personnel should be tested at regular intervals for safety-conscious work habits.

1.7 Obligations of the trainees

All persons who have been entrusted to work with the system undertake to complete the following steps

before beginning work:

 Read the chapter concerning safety and the warnings in this manual

 Observe the basic regulations on occupational safety and accident prevention.

Introduction

10 © Festo Didactic CP Lab conveyor

2 Introduction

2.1 Warranty and liability

In principle all our „Terms and Conditions of Sale“ apply. These are available to the operating authority

upon conclusion of the contract at the latest. Warranty and liability claims for persons or material damage

are excluded if these can be traced back to one or several of the following causes:

 Use of the system not in accordance with its intended purpose

 Incorrect assembly, commissioning, operation and maintenance of the system

 Operation of the system using faulty safety equipment or incorrectly fitted or non-operational safety or

protective devices

 Non observance of notes in the manual regarding transport, storage, assembly, commissioning,

operation, maintenance and setting up of the system

 Unlawful constructional modifications on the system

 Inadequate monitoring of components subject to wear

 Incorrectly carried out repairs

 Catastrophes as a result of foreign bodies and vis major.

Festo Didactic herewith rules out any liability for damage or injury to trainees, the training company and/or

other third parties which may occur during the use/operation of the system other than purely in a training

situation, unless such damage has been caused intentionally or due to gross negligence by Festo Didactic.

2.2 Important notes

The basic requirement for safe use and trouble-free operation of the system is to observe the fundamental

safety recommendations and regulations.

This manual contains important notes concerning the safe operation of the system.

The safety recommendations in particular must be observed by anyone working on the system.

Furthermore, the rules and regulations for the prevention of accidents applicable to the place of use must be

observed.

Introduction

2.3 General information CP Lab system

The Festo Didactic Learning System is designed to meet a number of different training and vocational

requirements. The modules of the CP Lab are industry-orientated vocational and further training. The

hardware consists of didactically for didactic training industrial components.

The stations provides an appropriate system for practice-orientated education/classes of the following key

qualifications

 Social competence,

 Technical competence and

 Method competence

Moreover, training can be provided to instil team spirit, willingness to cooperate and organizational skills.

Actual project phases can be taught by means of training projects, such as:

 Planning,

 Assembly,

 Programming,

 Commissioning,

 Operation,

 Maintenance

 Fault finding and

 Trouble shooting.

This manual describes the handling of the pallet transfer system. It contains explanations and descriptions

of all the processes required for operation. Facts are partly described with the help of graphics or images

sub serving an easier understanding.

The CP Lab system is developed for all apprentices who want to move something. It doesn’t matter if the

education is for electro- or metal profession, for mechatronics, technician- or engineer education.

Concept

During technical lessons for pupils we use our simple models with O-ring drive. In the CP Lab system the

material flow is realized with a common industrial belt. In industrial, automated production, special belts are

essential part of the production system. Products with different measurements are transported on belts with

different widths or on double belts.

Transfer system with modules

The transfer system is a modular system which consists of two essential components. First the transfer line

which can be equipped with different drive concepts and second the constitutive modules for topics like

sensors, electrical positioning, handling, assembling, camera inspection, barcode scanning, RFID and many

others.

Introduction

12 © Festo Didactic CP Lab conveyor

2.3.1 Application modules

 CP application module output

For removing workpieces from the system

Complexity medium, electro pneumatic module

 CP application module drilling

For drilling housing parts

Complexity simple, electro pneumatic module

Introduction

 CP application module iDrilling

For drilling housing parts

Complexity simple, electro-pneumatic module with controller with web interface for cyber-physical

system

 CP application module labeling

In order to label workpieces with a label

Complexity high, electro pneumatic module

Introduction

 CP application module manual work

For the manual processing of pallets and / or workpieces on a stopper

Complexity simple, software module

 CP application module Camera inspection

With camera for checking object properties

Complexity high, Festo Camerasystem with evaluation software

Introduction

 CP application module magazine

For feeding housing parts. Different in the magazine rear cover and magazine front cover

Complexity simple, electro pneumatic module

 CP application module Measuring

For quality assurance

Complexity high, processing of analog input signals

Introduction

 CP application module Muscle press

For pressing the housing parts

Complexity simple, electro pneumatic module (pneumatic muscle)

 CP application module Pick by light

Hand workplace where workpieces are provided for assembly.

Complexity, electrical module

Introduction

 CP application module press

For pressing the housing parts

Complexity simple, electro pneumatic module

 CP application module heat tunnel

For heating workpieces for thermal processing

Complexity medium to high, control engineering module with analog processing and PWM

Introduction

 CP application module turning

For turning workpieces

Complexity medium, electro pneumatic module

Introduction

2.4 Resources

The training equipment of this system consists of several resources to be used depending on the process

selection.

The following resources are available:

Carrier

These carriers are available for the transport of the pallets.

Pallet

These pallets are available for receiving one workpiece each.

Introduction

External production parts

Workpiece

description

CP back cover

No. 111

CP – Platine

Nr. 120

CP Fuse

Nr. 130

CP front cover

No. 110 - Is a CNC milling machine in the plant, the front cover can also be produced there and thus

becomes the production part.

Production parts

Workpiece

description

workpiece

description

CP without fuse

No. 211

CP customer part without fuse

No. 1211

CP fuse left

No. 212

CP Customer part with fuse left

No. 1212

CP fuse right

No. 213

CP Customer part with fuse right

No. 1213

CP both fuses

No. 214

CP Customer part with both fuses

No. 1214

CP customer part

No. 1210

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Festo CP Lab User manual

Festo CP Lab User manual

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